Massive construction system using rock masonry

ABSTRACT

A construction system for massive dwellings or alike; a unit shall be built in 5 days after preliminary work. First, shall be prepared precast items: sills and headers, using templates and reinforcing them to resist shear and diagonal stresses; and exterior and interior wall molds to use numerous times. Then foundation shall be set to have a slab floor with pipes inside a steel structure, and wall molds erected on each side of it, following a predetermined color and graphic code. Afterwards, shall be inserted precasts and all openings of building to pour concrete masonry and form a monolithic structure. A steel structure shall be embedded on top of walls for anchoring concrete T-beams. A material to insulate and form a stem of said T-beams shall be put on platform surface, and then a metallic mesh for reinforcing said T-beams, and for setting pipes, lastly, concrete shall be poured over.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not applicable.

REFERENCE TO A SEQUENCE LISTING, A TABLE OR A COMPUTER PROGRAM LISTINGCOMPACT DISC APPENDIX

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of Invention

This patent application falls in the “Construction System's” field. Itis a method to produce massively dwellings or any buildings at anaffordable cost from preliminary planning to all other constructionsteps: foundation, walls, roofing, finishing, cleaning and delivering.The System is using several prior arts, which are improved and combinedtogether to accomplish a method capable to produce high volumes ofdwellings at an affordable cost, and in a short lapse, and withoutemploying expertise labor.

2. Description of Prior Art

(a) Masonry Wall Construction

Masonry wall construction is a very old building practice; in the Greekisland of Thera (known as Santorini) the mortar used was the localvolcanic soil. This practice was successful but slow.

In the Imperial Rome, the inventive mind of the Romans and theavailability of volcanic sand with cementing properties, crafted amortar to cast masonry with natural stone, or ruble from demolition; thePantheon in Rome, built circa 123 A.D., is one among many still standingin our era. Although Romans accomplished such long standingconstructions using a system of “lost molds” (two parallel brick wallsfor casting masonry,) had to withstand a time-consuming production sincethese brick molds were incapable to hold the lateral forces of all theliquid mortar necessary to fill said lost molds to the expected heightin one pour, as a result was done in rows after rows. Furthermore, thissystem was possible because slavery was legal in Roman times, so atitanic inexpensive labor crew was feasible for handling too heavyduties.

(b) Conventional Masonry Construction, Currently Used.

This system calls for several construction materials, such as stonemasonry, concrete blocks, clay bricks, and the like to build walls. Theconstruction must be coordinated with the footing construction, and aqualified labor as well as supervision to perform several demandingtasks.

Besides, after walls have been built, electrical, plumbing pipes, andoutlets are installed, consequently said walls are later on scoured andpatched. Furthermore, headers for door and window openings, and door andwindow frames must be put, having one make use of more constructionsupplies that in time get cracks in between, so their exterior perimeterhave got to be caulked and maintained.

In addition, delivery of materials and their reception with all theclerical work involved has to be handled, making the whole process timeconsuming and highly costly.

(c) Wood or Metallic Framing Walls.

The framing construction requires qualified labor and close supervisionof anchors, especially for certain sections of walls capable ofresisting earthquakes.

Connecting metallic members with nails or setting directions isdifficult, that on occasions workers who do not understand instructionsskip them and supervisors do not notice that omission, and as aconsequence the desired quality of the structure is not quiteaccomplished.

Although metallic framing is better than wood framing regarding termitesand flammability, requires more specialized labor and tight supervisionmaking the system expensive.

Further, to make walls from both framing systems it is needful toplaster exterior or apply a siding material on perimeters, and for aninterior face and partition walls gypsum board is normally used.Thereafter a furring process which requires specialized labor, plusshear reinforcement and installation of windows and doors with all thecomplications of caulking, flashing and leveling. Whilst, if insulationis required, rigid insulation is expensive to use and blanket insulationrequires wider depth for higher values, condition which asks for anincrease in the width of the walls, as the items used called studs needto be wider, or use a double framing and a rise in costs.

Finally, delivery and reception of materials need lots of clerical work,causing time consuming and all the process is highly costly.

(d) Prefabrication System.

Prefabrication involves lots of materials: steel, aluminum, wood, panelsof combined materials including plastics, and even concrete, mainlylight weight concrete. Moreover to assemble a building usingprefabricated elements encompass several conditions because of beingproduced by industrial means, increasing costs and making such systemmore fancy than effective.

It also requires a factory, specialized machinery, technical personnel,and a market absorbing the planned production, and enough storage spacefor the elements in stock, as delivery of materials and reception withall clerical work involved.

All the process is time-consuming and complex, since fabrication limitsthe amount of units to be built as availability of elements is thefunction of the factory's production. This system cannot solve a highdemand of dwellings for a disaster solution.

As a final inconvenient point, design solutions depend on the modulardimensions hence, limiting innovation, flexibility, and functionality.

BRIEF SUMMARY OF THE INVENTION

The present invention is aimed at producing massive amounts of dwellingsand the like, sorting the positive advantages of reliable prior arts,and coordinating, and translating them to our present times to producestrong, monolithic enclosures at an affordable cost, which overcomes theforegoing drawbacks of the conventional arts after a combination andimprovement of them.

It is an object of the present invention to provide a method, based onconcrete masonry and precast concrete accessories, a construction lapsecompressed in five days for one building unit, as follows:

-   -   On the first day shall be built the waste lines, foundation, and        floor slab.    -   On the second day, by means of specially designed molds and        precast items: walls shall be cast; windows and doors shall be        installed to finally have a monolithic unit.    -   On the third day a reinforced concrete slab shall be put in        place, whilst concrete additives shall be used to remove the        formwork safely the following day.    -   On the forth and fifth days shall be installed bath and kitchen        fixtures, and finishing details shall be performed, such as:        floors, roofing, and painting.    -   After cleaning, at the end of the fifth day, one story dwelling        shall be delivered.    -   A multistoried building takes additional time.

The set of molds of each phase: foundation, walls, and roof shall bemoved to the next site every day; thus, shall be produced a finishedbuilding every day from the fifth day of starting the construction. Thenumber of units delivered a day shall depend on the number of sets ofmolds to be used.

ADVANTAGES OF THE PRESENT INVENTION

The use of the present invention not only will provide housing andrelated buildings to a world wide exploding population at a fair cost.

The present invention starts the construction process by obtaininginformation of the working conditions and requirements, in order to do aspecific design and plan of action. Consequently, an open forum ofdiscussion for the design solutions regarding budget and time frame,evaluating resources and geographical limitations for example weatherand seismic conditions. Traditional and social constraints will also beconsidered. All this intellectual and technical implementation incomparison with other construction systems, which only follow traditionswithout making the players part of the solution, provide a furthereducation for the personnel involved in the use of the presentinvention.

Another object of the present invention is to provide the necessarytraining to the work force in order to use efficiently the system,creating a new working expertise and education skills which can improvethe social environment of the workers, and related personnel to theconstruction process.

Another object of the present invention is to provide special precastitems such as headers, and sills to complement windows and doorsopenings. These precast items lower costs and increases speed with highresults in the construction process.

Another object of the present invention is to design a set of wall woodmolds, using traditional techniques, but with improvements which whenutilizing every day can be used 30/40 times.

Another advantage of the present invention is to provide a low cost inmaintenance because concrete masonry is waterproof, for this reason, nooxidation risks arise providing a long lasting performance. What's more,no termite attacks; and no use of construction materials as lumber,thus, natural resources undermining is avoided.

Another advantage of the present invention is to provide the possibilityto build walls with all the ginger bread, when desired by the user, andno additional specialized labor or cost. Since one of concrete'sattributes is that it molds into any shape of any special mold, creatinga final structure that has the shape, line and volume of any dimensionone may require.

Another advantage of the present invention is to provide no limitationof shape, size, or functionality; as walls can be of any desiredthickness, appearance, and functionality; and alcoves to containinsulation materials can be added, etc.

Another advantage of the present invention is to provide a strong andlight roof structure of reinforced concrete, type known as T-beams,which uses a small volume of concrete to cover a comparable long span.

Another advantage of the present invention is to provide a costreduction in improving the thermo function of the roof, by using eitherinsulation or alternate material to form the T-beams' stem.

Another advantage of the present invention is to provide a place toembed electrical, plumbing or other pipes protecting these main elementsfrom damage as a consequence of using reinforcement for the concrete.

Another advantage of the present invention is to provide an earthquake,fire; termite, hurricane, and flooding proof construction due toconcrete masonry's characteristics, and the monolithic nature of thestructure.

All the foregoing advantages distinguish the present invention as apowerful construction system of dwellings and the like, in improving andcombining prior art, besides, introducing some new items and concepts.Giving the building industry worldwide the opportunity to satisfy theneed of affordable constructions at massive production levels.

Furthermore, another important advantage of the present invention isthat it has no limited scope regarding building type; as it is fittingfor the construction of dwellings, schools, commercial buildings,offices, and medical services, hotels, etc., one level or multiplestories, and can be simple or trendy according to the ability of whodesigns the particular architectural style. The use of the presentinvention will improve the construction industry worldwide, creatingjobs and increasing business in massive numbers.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing Summary as well as the following Detailed Description ofPreferred Embodiments is better understood when read in conjunction withthe appended drawings. For the purpose of illustrating the invention,there is shown in the drawings embodiments which are presentlypreferred. It should be understood, however, that the invention is notlimited to the specific methods and instrumentalities disclosed.

FIG. 1 is an exploded isometric view of the preferred embodiments of thepresent invention.

FIG. 2 is isometric sketches of precast items, and anchor structure.

FIG. 3 is a series of sketches of the operations to produce the footingsand floor slab in the first construction day.

FIG. 4 is a series of sketches of a construction sequence to set thewall molds.

FIG. 5 is a series of sketches of a construction sequence to installwindows using the precast sill and header before pouring concretemasonry for walls.

FIG. 6 is a series of sketches of a construction sequence to installdoors: exterior or interior using the precast header before pouringconcrete masonry for walls.

FIG. 7 is a series of sketches of a construction sequence to pour themasonry concrete into the walls in the second day of construction.

FIG. 8 is a series of sketches of a construction sequence in building aT-beam roof, and rigid insulation or hollow concrete blocks are used tomold the stems.

FIG. 9 is a bar graphic describing times and actions to accomplish theconstruction of a dwelling unit in five days

No more drawings are necessary, because the following fourth and fifthday of construction, are used to install bath and kitchen fixtures,glazing, painting, flooring, roof waterproofing and details. This partof the construction uses conventional systems.

DETAILED DESCRIPTION OF THE INVENTION

To facilitate the understanding of the drawings and/or writtendescriptions, a key number is listed below:

1. Foundation

-   -   This includes: footings with a shape, where the base is big        enough to distribute the imposed loads of walls and roofs to the        ground. A floor slab shall be of concrete 18 for floor finishes.        An anchor structure 6 a device half embedded where concrete        masonry walls shall be set, of the present invention, to connect        said footings with the walls.

2. Concrete Masonry Walls

-   -   Walls are elements to enclose spaces from the weather, noise,        etc. plus providing privacy. Walls definition includes openings:        doors and windows. In the present invention solid walls are        built with a concrete masonry 17+18, and the openings use        precast headers 4 and precast sills 5, whilst windows frames,        and doors frames, and leafs can be of any material, brand or        manufactured in construction site. The present invention denotes        the molds modifications to make use of the foregoing.    -   At the top of walls shall be embedded anchor structure 6        anchoring thereof as footing, because the structure holds beams        of roof with walls creating a monolithic structure, a feature of        the present invention.

3. Roof (Proposed in the Present Invention)

-   -   It is of concrete referred to as T-beams 37 as it consists of        beams with a T-shape, having a long steam with a narrow base at        the vertical part of the T. This steam shall be reinforced with        a steel structure 26 where the rod elements resist flexion        stress in the lower part of the structure, held together with        stirrups (bent rods, usually in a U-shape or a W-shape), and        also holds metal mesh 27.    -   Said metal mesh 27 is an arrangement of steel bars or wires        normally in two directions at right angles, tied or welded at        intersections; a reinforcement of the horizontal bar of said        T-beam 37.    -   Said T-beams shall be set at equal distances one from the other,        condition which defines T-beam system. To assure the equal        distances, and build easily the stem, and give roof insulation        (additional quality) the present invention uses rigid insulation        panels 24 for extreme weather conditions, or hollow concrete        block 25 for less critical conditions. For buildings without        snow endurance one quarter per inch per one foot slope shall be        used, by thickening the slab were necessary. On the other hand,        for snow conditions roof beams can be built at any pitch        required.

4. Precast Header

-   -   This is an accessory element to enclose the top of openings        where doors 29 or windows 28 shall be located. It is build with        reinforced concrete 18 and a structure of rebars and stirrups 34        and molds that shall rest on the ground and be cured 38 for 7        days without moving them to reach complete resistance, as        required.

5. Precast Sill

-   -   This is another accessory element to enclose bottom of openings        where windows 28 shall be located. It is build with reinforced        concrete 18 and a structure of rebars and stirrups 34 and molds        shall rest on the ground and be cured 38 for 7 days without        moving them to reach complete resistance, as required.

6. Anchor Structure

-   -   Used in between footings and wall, and between walls and roof        This is a structure of rebars and stirrups, with a width of two        inches less than the width of the wall, covering one inch at        each side forming part of wall 2 at the bottom attaching walls        to foundation footings, and at the top attaching walls 2 to roof        3.

7. Perimeter Foundation Molds

-   -   The molds for forming an exterior face of the foundation        footings can be of wood, using wood stakes and wood bracing to        set them vertically. Building them shall be under any        conventional system, however, the dimensions shall be the ones        described in the drawings because the idea is to have unskilled        labor use them at least 40 times. Also, shall have a color code        to locate them properly, hence, a red band in the front, blue in        the right side, yellow in the left side, and green in the back        side, plus black marks 32 with pointed arrows to show where        ditches are going to be and width of them. All shall be clearly        marked. This is part of the present invention to have an        automatic construction.

8. Exterior Wall Mold

-   -   The exterior molds shall be fabricated in the site using three        quarters inch or thicker water resistant plywood panels of four        by eight feet. Mold dimensions and/or panel material can be        different if necessary. Drilled holes 36 are necessary to hold        the molds at a parallel distance with ties 14 (said ties        generate the thick of the wall.)

9. Wales

-   -   To keep molds aligned. The exterior molds 8 and 13 shall be        reinforced with wales 9, a horizontal timber or beam, used to        brace or support an upright member for formwork. This piece of        lumber shall be two by four inches nominal by four feet long,        nailed to plywood at the bottom of drilled holes 36 keeping the        holes clear. Another row of wales 2×4 inches nominal by eight        feet long shall be placed on top of said drilled holes 36 after        ties 14 are in place, this 2×4×8 shall be placed in alternated        positions in order to keep plywood molds aligned when tightened        with the wedges 15. Once wedges are tightened, bracing 10 shall        be used to plumb the formwork properly.

10. Bracing

-   -   Used in the present invention to plumb formwork. It is light        formwork pieces of lumber 2×4 inches nominal by eight or ten        feet long, sufficient to brace the formwork to an upright        position. Some stakes shall be pounded into the ground to nail        one end of the bracing, creating an angle to support upright the        molds.

11. Plumbing Pipes

-   -   This refers to the main pipes which carry water and connect to        secondary water pipes for feeding faucets installed in a        building.

12. Electrical Pipes

-   -   These are the main pipes to contain wires connected to secondary        pipes and boxes for distributing electrical power in a building.

13. Interior Wall Mold

-   -   It refers to the opposite of mold 8 and has similar        specifications to said 8. It shall have 36 holes as well and        wales 9. No braces are necessary because once the ties 14 with        the wedges 15 are tighten, the framework shall be plumb.

14. Ties

-   -   They are separator wall items. They have several shapes and        there are several brands in the market, the ones shown in the        figures are only a sample of one of them.

15. Wedges

-   -   They are used in conjunction with ties 14 to tight the molds to        be filled with rocks 17 and concrete 18 as denoted in the        present invention, as required. Wedges need to match with the        chosen brand ties 14.

16. Scaffold

-   -   The word which defines a temporary platform for supporting        workers and materials on the face of one structure and to        provide access to work areas above the ground, as shown in        FIG. 7. It can be built under any safe conventional system with        lumber or one of those in metal leased in the market till used.

17. Rocks

-   -   In the present invention, it is the material used in high volume        to produce said footings and walls 2. Rocks are 60 to 75 percent        of the total volume. Rocks shall be the material of choice if        they are abundant in the construction area, which means: no        cost, to keep the final construction cost competitive. But, it        is not a restrictive condition because the complement material,        concrete 18, has the characteristic of being a material produced        using engineering techniques to decide how much resistance shall        be to compression stress. Making it possible to use any        acceptable option of material to substitute said rocks, for        example with ruble from fallen buildings due to natural        disasters, war, or other causes, or tree trunks, or coconut        shells, or chopped used tires, etc., to serve as a volume saver        in the concrete masonry. The only condition shall be size; thus,        the dimension shall allow the material go easily into the space        in between molds.

18. Concrete

-   -   Defined as a composite material consisting essentially of a        binding medium within are embedded particles or fragments of        aggregate. In the present invention shall be used Portland        cement concrete, but it can be substituted by other types of        concrete after studies prove it a suitable substitute. The        mixture of sand, gravel, Portland cement, and water can be used        under calculated proportions to have the wanted strength        required; fiber glass also can be added to improve the        characteristics of resisting tension of concrete. All the        technical advances, plus it's capability of taking the shape of        the mold where is poured, makes concrete a very workable        material.

19. Wood Stick

-   -   A rough tool, of a two by four inches lumber and eight feet        long, one for wales 9, and others for workers to manually push        rocks into concrete, while standing on the scaffold 16.

20. Trapezoidal

-   -   A metallic accessory with a tubular shape designed to be        embedded in concrete on top of walls, for holding with screws        lumber or manufactured metallic connectors, used with beams as        an alternate roof construction, instead of concrete T-beams.        Also this tubular accessory can be embedded at the face of walls        or under the T-beams stems to attach furring panels with screws        for wall or ceiling finishing.

21. Graphic Representation of an Exterior Wall Built with ConcreteMasonry, used in FIG. 8.

22. Graphic Representation of an Interior Wall Built with ConcreteMasonry, used in FIG. 8.

23. A Conventional Structure of Posts and Beams

-   -   Reinforced with diagonal lumber as braces, to support a platform        for workers to handle materials on it, necessary to build a        concrete slab

24. Rigid Insulation

-   -   This consists of boards of different materials available in the        market to provide insulation to roofs 3 and exterior walls 2.        The present invention uses these boards for roof insulation and        also, to mold the stems of T-beams 37.

25. Concrete Masonry Units (CMU)

-   -   Known as a block or brick cast of Portland cement used to lay up        with other units as in normal stone masonry construction. In the        present invention hollow Concrete Masonry Units are used as an        alternate material to 24 to mold the stems of the T-beams roof,        and also as an insulation material for non extreme climatic        conditions. Laying CMU in a horizontal way, the hollows will be        connected making the trapped air in them act as insulation.

26. T-Beam Reinforcement

-   -   In the present invention, metal bars, rods, wires, or other        slender members, previously designed by structural engineering        calculations, are embedded in the concrete forming the stem,        vertical part of the T-shape, in such a manner that the metal        and the concrete act together in resisting the forces from loads        of living traffic and/or wind, snow, and others imposed to the        roof

27. T-Beam Metal Mesh Reinforcement

-   -   The horizontal shape of the T uses an arrangement of steel bars        or wires, normally in two directions at right angles, tied or        welded at intersections or interwoven. This mesh reinforcement        is tied to the top rod of each of the T-beam reinforcements 26,        letting the mesh hang loose on the top of either one: 24 or 25        stem/insulation materials.

28. Window

-   -   Any type of chosen window: wood or metallic, but provided with        two anchors 35 at the back of its jambs to keep the window frame        firmly attached to the concrete walls.

29. Exterior Door and Frame

-   -   It shall be metallic wood or metallic, and shall have three        anchors 35 at the back of both jambs to hold it to the concrete        walls.

30. Interior Door and Frame

-   -   It shall be wood or metallic, provided with anchors 35 at the        back of its jambs to hold it to the concrete walls, the windows        28 and the doors 29.

31. Waste Lines under Concrete Slab

-   -   Refer to an installation of pipes for trapping waste from toilet        bowl, lavatories, kitchen sink, washing clothes machines or        boards, and other fixtures. Used for cleaning purposes or        disposal of feces and urine.

32. Painted Sloping Strip Marks in Molds

-   -   To be guides to aid laborers. Different colors shall be used for        different actions, for example, short parallel lines on the        interior of the perimeter foundation molds 7 shall instruct        workers where to dig a trench for a footing.

33. Returns

-   -   These are nailed strips of lumber at a right angle to the        interior face of wall molds 8 and 13 to hold in place door        frames and precast items during concrete masonry pouring, in the        present invention, for walls construction. They are made of a        lumber of 2 inches thick by half of the jamb's dimension minus        width of the wall. The length equals to the wall's height.

34. Precast Reinforcement

-   -   In the present invention it is metal bars, rods, wires, or other        slender members, previously designed by structural engineering        calculations, embedded in the concrete of the precast elements,        in such a manner that the metal and the concrete operate        together in resisting the forces from loads imposed on them.    -   The reinforcement shall consist of two rebars, one at one and a        half inches from the top of the precast, and the other at one        and a half inches from the bottom. These rebars form a structure        with rod stirrups or hangers. The stirrups are usually made of        rods of one quarter inch less in diameter than the rebars, and        in U-shape bents; the bents are for holding said rebars, which        are attached with an 18 gauge twisted wire. Said stirrups or        hangers are at distances of no more than four inches center to        center.    -   This reinforcement is a must for said precast items to resist        shear and diagonal stresses, since it carries out the function        of beams. Structural calculations (mathematical calculation        based in formulas obtained by trial and experience to find the        dimensions of the different elements used for forming a        structure capable to resist the forces acting on them, this task        falls in the field of the engineering) shall be necessary to        verify diameter dimension of the rebars and rods; and concrete's        compressive strength shall not be less than 5000 pounds per        square inch, tested for twenty-eight days. There shall only be        changes to the compressive strength if a structural calculation        recommends it.    -   Said precast items shall be cured for al least seven days after        concrete pour at a temperature above 50° F.    -   Wood molds in general shall be prepared using templates to make        its production automatic.

35. Metallic Elements

-   -   Those attached to windows 28 or doors 29 at the back of their        jambs, shall provide anchorage to such windows or doors at the        walls opening ends. The attachment of 34 can be by welding when        28 and 29 are of steel. Screwing 34 can be the attachment system        for aluminum 28 and 29 or when wood or similar materials are        used in its fabrication.

36. Drilled Holes

-   -   Holes drilled to wall molds 8 and 13 shall be at the dimensions        required to let ties 14 pass thru. The distance in between holes        and number of holes per mold are per engineering calculations,        considering the width and the height of the wall. Once the        specifications are calculated one piece shall be drilled        carefully, such piece shall be used as a template to drill all        the ones used in the construction process.

37. T-Beams

-   -   A reinforced concrete beam having a cross section resembling the        letter T. This concrete roof system is very effective to save        long spans with a short volume of concrete 18 in light        reinforcement 26. Extensively used in parking structures and        factories construction but, its use in light constructions is        not popular, as result of the cost involved by molds and labor        in forming the stems of the T-shape. The present invention uses        rigid insulation 24, which is necessary for buildings in extreme        climates or the hollow concrete units 25 for non extreme        climates. The use of 24 or 25 in the present invention overrides        the cost of forming stems, making the T-beams used at a highly        competitive cost. Besides, the engineering calculation        techniques of the present invention let the support platform 23        be moved to the next location, the day after pouring onto roof,        keeping the construction pace in schedule.

38. Curing

-   -   Refers to keeping placed concrete humid during some definite        time because concrete hardening is a chemical reaction that uses        water to harden it properly and if there is not enough water        during the chemical process the concrete cracks, making the item        not what was expected.

39. Trowel Finish

-   -   A smooth-concrete-finished surface produced by a flat tool.

To use the present invention the process starts with the listing of theprogram's requirements regarding:

-   -   General concept

The present invention massive CONSTRUCTION SYSTEM at an affordable costbased on the use of concrete masonry and unskilled labor to producedwellings and the like.

-   -   Basic Construction System, is illustrated by the FIG. 1, which        shows an exploded sketch of three basic elements:        -   Foundation.        -   Walls.        -   Roof            Foundation 1,

The present invention shall use concrete masonry 17+18, and the proposedmolds 7 specially designed to produce one foundation unit per day. Saidmolds shall be used in an automatic manner thanks to a color code 32 (adetailed sequence of steps to build foundation and related elementsmarked on said molds) refer to FIG. 3.

Walls 2,

The present invention shall built a solid continuous surface usingconcrete masonry 17+18, (see FIGS. 4 and 7 for detailed information ofplacing molds and pouring concrete masonry) according to thegeographical location by adjusting its shape and process in building, asavailability of construction materials, climate variations, seismicforces, flooding, etc. shall be considered. Penetrations of doors andwindows are discussed in detail FIGS. 5 and 6.

Also the Construction System in the present invention can be customizedto a certain economical circumstances such as a limited budget, and asocial and/or ethnical architectural style, and to a critical conditionwhich is the availability of the construction materials and labor.

Regarding the foregoing the present invention as a Construction Methodshall not be limited to the physical characteristics shown in theattached drawings, but shall use technical knowledge in general to solveany special circumstances to provide a solution in building swiftly andat an affordable cost to satisfy the needs in whatever constructionsite.

Roof 3,

Construction in the present invention shall be with concrete 18 T-beams37, a shape that can be obtained using rigid insulation 24 whenrequired; or hollow concrete blocks 25 for places with mild weather; orfactory produced fiber glass molds to create a coffered shape.

An alternate roof construction of lumber, wood trusses, thatched onthree branches, etc. can be used, with a simple change in the anchoringconnection used for holding roof structure on top of the concretemasonry walls.

For a better understanding of the process it shall be divided into fivesections:

-   -   1. “Preliminary Work”    -   2. “Foundation”    -   3. “Walls”    -   4. “Roof”    -   5. “Finishing”

1.—Preliminary Work

As follows:

At first shall be carried out discussions about the Construction Methodwith the personnel in charge of the construction to set conferences fortraining labor, because it is important the labor personnel understandhow their work shall contribute to the success of the aim, and toclarify the construction techniques contained in the present inventionbecause they are different in approaches and goals from conventionalones. Also, to enhance the idea that the present invention approachesmassive construction in a short time, and the goal is to buildaffordable dwellings or any building. Locating and designating an areato produce all precast or preassembled items needed for the inventionshall be done, to have the present invention running swiftly.

(See FIG. 2) Precast items: headers 4 and sills 5 shall all be made ofreinforced 34 and concrete 18, in the designated area referred above.

(See FIG. 4) In the preliminary task for wall molds, exterior 8 andinterior 13, holes 36 shall be drilled into panels of plywood, normallyof four by eight feet, and then shall be nailed three 2×4 wales 9 toreinforce 8. Different location of holes 36 and dimensions of theplywood, as well as dimensions and number of said wale 9 shall depend onthe walls' width, height, location, and/or special constraints, or usesof the building to be built.

2.—Foundation

Actual construction starts with the foundation for one unit. See FIG. 3,as follows:

(FIG. 3A) Grading levels. A similar shape and form of the ground underand surrounding the constructions shall be required to let rainwater ranfreely without going inside the building.

(FIG. 3B) Waste lines 31 under concrete slab. An excavation shall berequired to have trenches for installing pipes that trap waste forcleaning purposes or disposal of feces and urine.

(FIG. 3C) Said waste lines 31 set in place. Said pipes shall beinstalled on the slope to connect end of the line to a main waste lineor septic tanks, depending on the infrastructure available at theconstruction site.

(FIG. 3D) Placement of exterior perimeter molds 7. By following theinstructions discussed in the conferences of Preliminary Work andconsidering the location of buildings in drawings. Said exteriorperimeter molds 7 for first building shall be set by a trainedsupervisor, using dimensioning and leveling tools, and the next onesshall use the first one as datum for a swift placement of the molds 7.This and other tasks are the items for discussion and understanding inthe said Preliminary Work.

(FIG. 3E) It shall be dug trenches following the perimeter molds 7.

(FIG. 3F) It shall be dug trenches for interior footings followingpainted marks 32 located on said molds. The depth of the trenching shallbe enough to retire contaminated soil, whilst earth from the excavationshall be deposited in between trenches.

(FIG. 3G) Trenches shall be filled with one layer of big rocks 17 togive room for the next task.

(FIG. 3H) Concrete 18 shall be poured on said rocks 17 using concretevibrators to make said concrete move in between said rocks, fillingvoids.

(FIG. 3I) Operations (g) and (h) shall be repeated until reaching eightinches (20 centimeters) plus o minus below the top of the perimeter ofsaid molds.

(FIG. 3J) A layer of rocks 17 shall be placed on the area in betweenfootings, these rocks can be of any dimension as long as when laid downform a flat bed and after a concrete mat is poured forms a slab floor ofaround four inches high, a horizontal finish floor level. This layerworks as a cushion in case of an expansive soil condition. Expansivesoil, has the characteristic of reducing greatly its volume when dry,but comes back bigger with moisture. This condition breaks the concreteslab floor very easily. In the General art metal mesh is used, similarto 27; but in the present invention shall be used rock beds, whichguarantee space for soil volume changes and works better than aconventional metal mesh.

(FIG. 3K) A structure of rebars and stirrups 6 shall be half embedded onsaid perimeter molds 7 when the concrete is still soft, leaving openspaces for doors and sills, as marked by the color code 32.

(FIG. 3L) Lastly, the floor surface shall be smooth with a metal handtool named trowel 39.

Then, cured 38 with clean water after the floor slab is hard enough totraffic without showing marks. A water hose can be used.

3.—Walls.

Construction of walls, see FIG. 4, as follows:

(FIG. 4A) One side of wood molds 8 shall be erected, this mold is theone reinforced with three wales 9 of a 2×4 (5×10 cms. nominal) wood andnailed, to keep molds aligned, and shoring elements 10 shall be used tobrace and to straighten them into a perfect vertical position.

-   -   Plumbing pipes 11 and electrical lines 12 and others shall be        set inside of the embedded structures of rebars and stirrups 6.        The structures 6 have a double function, one being a structural        connection in between foundation and walls, and another a        protector of piping lines from rock hits which may happen when        throwing rocks 17 during concrete 18 masonry pour if no        protection is considered.

(FIG. 4B) Once the wall molds are in place ties 14 separators forassembling wall molds, shall be inserted into the pre-drilled holes 36of the molds 8.

(FIG. 4C) Then, ties 14 shall be inserted into the pre-drilled holes 36of molds 13.

(FIG. 4D) Wedges 15 shall be used at the two ends of ties 14 to tightentogether said molds 8 and 13. At this point said molds for solid wallsshall be ready for concrete masonry pouring. This operation of pouringwalls with concrete masonry is shown in FIG. 7.

For window placement see FIG. 5.

(FIG. 5A) It is an exploded sketch showing precast sill 5 that shall beset against and in between nailed wood return pieces 33 of molds 8. Thewindow 28 shall be placed on top of sill 5.

(FIG. 5B) It is an exploded sketch showing said precast sill 5 againstand in between said nailed wood return pieces 33 of said molds 8. Saidwindow 28 shall be placed on top of said sill 5.

(FIG. 5C) It is an exploded sketch showing said precast sill 5 againstand in between said nailed wood return pieces 33 of said molds 8. Saidwindow 28 is now on top of said sill 5.

The two molds 13 are shown in an exploded position. Note that all wallmolds do not show holes 36 or wales 9 or braces 10 but all theseelements shall be present and used as before stated in FIG. 4.

(FIG. 5D) It is an exploded sketch showing said sill 5 against and inbetween the 33 of the 8. The 28 is on top of said 5, said two molds 13as shown in place, too, however, all wall molds shown do not show saidholes 36, said wales 9, either said braces 10, ties 14 and wedges 15,which shall be used to tight said 5, and said 28. Precast header 4 shallbe set on top of said 28 and in between said 33 attached to wall said 8and the 13 as shown in an exploded sketch. Note that said 33 have thedouble function of holding precast items and window or door frames, andthey are a stop forming the ends for the concrete masonry in betweenopenings.

Door placement, see FIG. 6, as follows:

(FIG. 6A) It is an exploded sketch showing door 29 or 30, an exterior orinterior door, which are similar, that shall be set against and inbetween nailed wood return pieces 33 of molds 8.

(FIG. 6B) It is an exploded sketch showing said door 29 or 30, againstand in between nailed said wood return pieces 33 of said molds 8.

(FIG. 6C) It is an exploded sketch showing the 29 or 30, against and inbetween the 33 of the 8.

Molds 13 are shown in an exploded position, too. Note that all the wallmolds shown do not show holes 36, wales 9, either braces 10, however allthese elements shall be present and used.

(FIG. 6D) It is an exploded sketch showing said 29 or 30, against and inbetween said 33 of said 8. Said 13 are shown in position holding said 29or 30. Note, once more all said wall molds do not show the 36, the 9,either the 10, ties 14 and wedges 15, which shall be used to tight said29 or 30. The precast header 4 is shown in an exploded sketch; it shallbe on top of said 29 or 30 and in between said 33 attached to said 8 and13. Said 33 have a double function: hold the precast items and said 29or 30, whilst they also are a stop forming the ends for the concretemasonry in between openings.

Pouring concrete masonry into molds of walls, see FIG. 7, as follows:

(FIG. 7A) After bracing and verifying the plumb of the molds scaffold 16shall be set and rocks 17 shall be put on the scaffolds to do thepouring.

(FIG. 7B) Concrete masonry cast into said molds shall start by fillingsaid forms 8 and 13 to two feet eight plus or minus of concrete 18 (amixture of cement, gravel, sand, and water at appropriate proportions tohave a 5000 pounds per square inch), a resistive quality.

(FIG. 7C) Once said two feet eight of concrete 18 are inside the molds,said rocks 17, which must be one dimension smaller than the distance inbetween said forms, shall be pushed using a 2×4 stick 19 into the softconcrete, one after another, until no said concrete is covering the topof said rocks. Then a second layer of concrete shall be placed on top,and another layer of rocks pushed once more into said soft concrete. Thefilling does not need to be in all said forms at the same time, thepouring can be advancing, thus a layer of 10 feet in length shall bepoured into a form end and said layer is not even in width but insteadof an approximate 45 degrees slope, to have rocks pushed into; and afterthat another layer of 10 feet in length shall be poured besides thefirst to have rocks also pushed into, and over again, till the bottom ofthe forms is covered with one layer of concrete masonry and ready forthe next. This helps to avoid concrete hardening and the next masonryplacing shall have a strong bonding.

(FIG. 7D) After filling said forms to the top, and before said concretestarts hardening, structures of rebar and stirrups 6 shall be halfembedded at the top of the walls.

(FIG. 7E) An alternate option, in case lumber or metal roof structuresshall be required, a screw item 20 shall be embedded instead at the topof said walls.

Once completed the foregoing operations, the work for the day is done,said concrete shall be dry in the following day and said molds shallseparate from said concrete because of a chemical reaction, a loss inwater reduces its volume, liberating itself from said forms. Thereforesaid forms shall be easy to move onto the next wall forming.

4.—Roof

Construction of roofs, see FIG. 8, as follows:

(FIG. 8A) This sketch shows a section of two exterior walls 21 connectedto a footing with a structure 6. Another structure 6 is half embedded asshown on top of said walls 21 that shall anchor concrete T-beam 37.Also, the sketch shows one interior wall 22 in between said exteriorwalls with a structure 6 half embedded on top to anchor the concrete andform a solid connection with T-beam 37 (shown in sketch 8E.)

(FIG. 8B) This sketch shows the same section of 8A, plus a conventionalstructure of posts, beams and a platform of panels, all under number 23(wood forms for supporting a construction of concrete slabs), in anschematic representation where bracing and base supporting posts areomitted for clarity.

(FIG. 8C) This sketch shows the same section of 8B, with saidconventional wood forms 23 for supporting concrete slabs. The surface ofplatform 23 has on top rigid insulation panels 24. The panels form astem of said T-beams 37 (shown in sketch 8E) and also providetemperature insulation to the roof

(FIG. 8D) This sketch shows the same section of 8B, with saidconventional wood forms 23 for supporting concrete slabs. The surface ofplatform 23 has on top an alternate option, hollow concrete blocks 25.This option can form the stem of said T-beams 37 (shown in sketch 8E)and also provide temperature insulation to the roof instead of saidpanels 24.

(FIG. 8E) This sketch shows a blow up section of the supporting platform23, and the stem forming/insulation, which can either be 24 or 25 asabove mentioned in (8C) and (8D). In addition, shows a metallic mesh 27used for reinforcing the slab that is part of said T-beams 37. Said slabshall also be used to install plumbing and/or electrical piping,embedded into concrete 18 of said T-beams 37. The triangular shapeembodies steel reinforcement structures 26. The broken line representsthe top of said concrete 18 that shall be poured in the next operation,when all the foregoing elements are in place. The ellipse marks oneT-bar 37 as one unit, which connects with the others to form all roof 3.

(FIG. 8F) This sketch shows the roof 3 after top of surface was smoothenwith a trowel finish 39. The sketch also shows a hose pouring water forcuring 38 after said trowel finish 39 and when said concrete 18 is stillsoft but supports traffic.

-   -   Said curing 38 shall be done at least 3 times a day for the next        two days. In hot climates shall require more curing as slab        dries faster, as said curing 38 shall be provided every time the        slab is almost dry.

The day after, 23 shall be moved to the next construction site to keepup with the work schedule. This is possible because the concrete shallbe mixed with chemical additives to accelerate the hardening chemicalreaction (there are several brands of additives in the market).Furthermore, instead of concrete 18 a fast set Portland cement can beused if available at the construction site. Engineering calculations forlaying down the proportions of Portland cement, sand, gravel, water andchemical additives shall consider moving a supporting platform the dayafter concrete pour. Also, in the present invention shall require thereinforcement 27 with bolder re-bars than the ones necessary whensupporting a platform for seven days, as in the conventional systems,however, using them for one day in the present invention reduces cost.

5.—Finishing.

The subsequent operations of painting, installation of bathroom andkitchen fixtures, glazing, details and others, are performed under anymethods being used in the area of the construction site, therefore, nomention is necessary. However, it is worth mentioning that female laborshall be used for these tasks because they are better in details andthus, more effective in finishing tasks and it can improve the economyby giving job opportunity to women.

From the foregoing description, it can be seen that the presentinvention comprises an easy and swift construction system of buildings.It will be appreciated by those skilled at the art that this is forcovering any architectural structure under any specification of use orarchitecture style. Although, the foregoing illustrated the basicmaterial for masonry construction as rocks, it can be substituted byanother material available in site, for example coconut shells, rubblefrom former buildings destroyed by wars or natural causes asearthquakes, or others, even old rubber tires. The function of the basicmaterial is to reduce the volume of concrete used. However, theadvantage of concrete is that it can be controlled, as the resistivestress can be customized by calculations of proportions of itscomponents: sand, gravel, cement and water.

It is understood, therefore, that this invention is not limited to theparticular construction material and shapes disclosed, but is intendedto use the material of construction in site, and any specification orstyle of construction defined by the appended claims.

FIG. 9

It shows a work schedule in a simple tabular form of a process to build40 units with a set of forms. Serving as the base to figure out how manysets are necessary to build the desired number of units in an expectedtime frame for a specific job.

I. A construction system for constructing massively dwellings or of thelike, that shall be at least in 5 days after preliminary work using rockmasonry, comprising: (a) preparing precast items, sills and headers forwindow, and sills and headers for doors using templates for, (b) makingwood molds, which can have any chosen shape and size, therebyaccommodate any type of opening of a building, (c) pouring into saidwood molds concrete, and after said concrete hardening, (d) reinforcingthe precasts with two rebars, one said rebar shall be at least one and ahalf inches from the top of said precasts, and the other one at leastone and a half inches from the bottom of thereof, so the reinforcementfulfills the function of beams, thereby said precasts shall resist shearand diagonal stresses, and in the intervening time, (e) drilling holesto exterior and interior wall molds, the molds can be at least of panelsof plywood, approximately of four by eight inches, and to said exteriorwall molds shall be nailed wales to of about two by four, to be usednumerous times in constructing numerous building units, (f) preparingone of various foundations where trenches are dug using a color code ofperimeter molds, (g) filling said trenches with one layer of the rocksthat are poured over concrete to form a slab floor which guaranteesspace for soil volume, and before concrete hardening (h) embedding astructure of rebars and stirrups on the perimeter for setting pipes ofat least plumbing, electrical lines, telephone lines, and televisioncable inside, thereby protecting them against rock masonry, and also foranchoring wall molds (i) erecting exterior wall molds following apredetermined color and graphic code to dispose the wall molds intotheir correct position, and using shoring elements to straighten saidwall molds into a perfect vertical position, on one side of thestructure and on the other side is erected interior wall molds followingsaid predetermined color and graphic code, and inserting ties of saidexterior mold into said interior molds to tighten both together, therebysaid structure is sandwiching said exterior and interior molds and readyfor (j) inserting the precast sill against and in between returns, onwhich is placed a window, and on which is placed the precast header, (k)placing a door against and in between returns, on which is placed theprecast header, thereby, holding all the foregoing items, and the wallsare ready for, (l) pouring into said walls concrete masonry, and beforesaid concrete hardening, (m)embedding a construction material on top ofwalls for anchoring concrete T-beams and firmly connect thereof to saidwalls, (n) setting on top of platform of a roof a material for providingtemperature insulation to roof and forming a stem of the T-beams,thereby, overriding the cost of forming stems of said T-beams, and (o)placing a metallic mesh on top for reinforcing T-beams, and for settingpipes of at least plumbing, electrical lines, telephone lines, andtelevision cable, and after reinforcement, (p) pouring concrete over andfinish the slab roof, leaving the supporting platform for a day, therebyis moved to the next construction site the following day to built a roofin one day, (q) whereby, said wall form and said pipes are swiftlyinstalled so costs are reduced in terms of paying hours work to thelabor, (r) whereby, said wall is not made of wood but relatively saidconcrete with said rocks or other material instead of said rocks costsare again reduced in terms of material cost. II. The construction systemof claim I wherein said using rock masonry, it is not constrained tosaid rocks since several other construction materials can be usedinstead of thereof, provided the material coheres well to concrete andthereof is a high percentage in volume of construction material used,thereby, possibilities are limitless, as ruble from a war zone ornatural disasters, used tires, ginger bread, and numerous othermaterials can be used instead of said rock. III. The precast items ofclaim I wherein said templates means for making said precast items'production automatic, thereby, as many as needed can be producedavoiding the precasts not being produced under specifications required,and the production done swiftly by unskilled labor. IV. The wood moldsof claim I wherein said opening of a building containing said openingselected from the group consisting of at least windows and doors, andpanels of glass or any other materials. V. The wood molds of claim Iwherein said concrete shall have a compressive strength no less than 500pounds per square inch. VI. The concrete of claim V wherein said thecompressive strength shall be tested for seven days. VII. Pouring intosaid wood molds of claim I wherein said concrete shall be cured for atleast twenty-eight days at a temperature above 50° F. without movingthem, after pouring. VIII. The reinforcing wherein said rebars form astructure with rod stirrups or hangers. IX. The rebars of claim VIIIwherein said rod stirrups mean stirrups of at least made of rods of onequarter inch less in diameter than said rebars, and in U-shape bents. X.The rod stirrups of claim IX wherein said U-shape bents mean for holdingsaid rebars with at least an 18 gauge twisted wire, and at distances ofno more than four inches center to center. XI. The exterior and interiorwall molds of claim I wherein said drilling holes mean drilling at adimension to let ties pass from end to end, and distance between theholes and number of said holes on the wall molds shall be according towidth and height of hereof under engineering calculations, thereby sizeof the walls is not restricted. XII. The perimeter of mold of claim Iwherein said color code means for indicating unskilled labor where todig said trenches, whereby, even the illiterate or foreigner labor canperform efficiently said digging. XIII. The exterior wall molds of claimI wherein said color and graphic code means for indicating unskilledlabor where to install the wall molds, whereby, even illiterate oroverseas labor can execute erection of said wall molds by the book. XIV.The precast of claim I wherein said return means nailed strips of alumber of 2 inches thick by half of jamb's dimension minus width length,with a length equal to wall's height, set at a right angle to theinterior face of exterior and interior wall molds. XV. The precast ofclaim I wherein said return means for holding openings of a building andprecast items, and a stop, as thereof shall outline the ends forconcrete masonry in between openings. XVI. The pouring into said wallsof claim I wherein said concrete masonry mean about two feet height ofconcrete, for sinking into said concrete rocks of a dimension no greaterthan the thickness of said walls and pressing with sticks to accommodateinto said concrete, and then repeating the same process of pouring saidconcrete and later said rocks until the wall forms are filled to thepeak. XVII. On top of walls of claim I wherein said a constructionmaterial containing the material selected from the group consisting of asteel structure of rebars and stirrups and trapezoidal pipes. XVIII. Theconstruction material of claim XVII wherein said steel structure ofrebars and stirrups means for a roof or deck that shall be of concrete.XIX. The construction material of claim XVII wherein said trapezoidalpipes mean for a roof or deck that shall be at least of metal or wood orjoists trusses or rafters for holding connectors for roof's elements.XX. On top of walls of claim I wherein said T-beams mean a reinforcedconcrete beam having a cross section resembling letter T. XXI. TheT-beams of claim XX wherein said reinforced concrete beam mean at leastmetal bars, rods, wires, or other slender members designed understructural engineering calculations and embedded into the concrete,thereby the metal structure and said concrete together resist at leastforces from loads of living traffic, and wind, snow and other conditionsimposed to roof XXII. On top of platform of claim I wherein saidmaterial for providing temperature insulation containing the materialselected from the group consisting of rigid insulation panels and hollowconcrete blocks. XXIII. The roof of claim I wherein said pouringconcrete shall consider engineering calculations for stipulating theadequate proportions of Portland cement, sand, gravel, water andchemical additives necessary to move a supporting platform the day afterthe concrete pour.